Method of making walls

ABSTRACT

The method includes providing, arranging, and mounting a line or series of studs, between parallel fixed structures of building so that each stud when as formed and mounted has a more resilient flange and a less resilient flange and so that the more resilient flanges of any two adjacent studs face in opposite directions; equally the less resilient flanges of two adjacent studs also face in opposite directions. 
     The method further includes the step of providing, arranging and mounting wall panels in staggered, alternated relation on the studs with the edges of two adjacent panels being secured to the less resilient flange of the same stud, and the center of each panel is adjacent the more resilient flange of a stud between the first named pair of studs. 
     The studs may have less resilient and more resilient flanges as originally formed, and/or only one flange may be anchored to the channels to make that flange less resilient than the unanchored flange. 
     In the mounting of the panels, the center of each panel has a bearing at a more resilient flange.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of my copending application Ser. No. 257,943filed May 30, 1972, now abandoned, which was a division of and copendingwith application Ser. No. 74,022, filed Sept. 21, 1970, and nowabandoned.

SUMMARY OF THE INVENTION

The present invention as specifically described in terms of thepreferred embodiments herein shown, relates to a method of constructinga sound attenuating wall between fixed structure, such as floor andceiling channels. In broad terms, the inventive concept includes first;

Providing, arranging, and mounting a line of studs between the fixedstructure so that the studs, when formed and mounted, have moreresilient flanges and less resilient flanges with the more resilientflanges of any two adjacent studs being alternately and laterallydisplaced, and second;

Providing, arranging, and mounting panels on the studs so that the edgesof two adjacent panels on one side are secured to the flange of one studof that side, with each panel bridging two less resilient flanges of twostuds and a more resilient flange of a stud between such two studs.

In the forming and mounting of the studs, the studs may initially haveflanges of different resiliency, or only one flange of each stud may beleft unanchored to the fixed structure to provide the attenuatinglimited resiliency, or both. The ultimate result is that the studs, whenformed and mounted, each has a more resilient and a less resilientflange, with the more resilient flanges of adjacent studs facing inalternate directions, and equally for the less resilient flanges.

In the mounting of the panels with the edges of two adjacent panelssecured to the less resilient flange of the same stud, the center of thepanel has a bearing at the more resilient flange of an intervening studof the side.

It is an object to provide for the proper use of a stud so made as toallow one to build staggered resilience into the wall.

While the method hereof may employ the stud shown and tested, this isonly one form of stud. If one took ordinary U-shaped metal studs andadhered 1/2 inch thick sponge rubber pads to one stud flange, one footon centers, or provided a sponge rubber strip and erected such a wall aswas done, the same test results might be achieved. Such a stud wouldthus have two sides or flanges of differing resiliency;

the less resilient flange mounts two adjacent panels on one side attheir adjacent edges;

the more resilient flanges are adjacent the centers of the same panels;

since the studs are alternately reversed, the same arrangement existsfor the opposite side of the wall;

and, thus by definition, a single stud has one side or flange, the lessresilient flange, at and fixed to edges of two panels on that one side,and the other side or flange of the same stud, the more resilientflange, is at or adjacent to the center of a panel on the same secondside of the wall.

Preferred forms of the invention are here disclosed in the followingspecification and claims to be read in conjunction with the appendeddrawings.

THE DRAWINGS

FIG. 1 is a fragmentary perspective view of a portion of the presentsound attenuation wall.

FIG. 2 is a fragmentary section taken in the direction of arrows 2--2 ofFIG. 1.

FIG. 3 is a fragmentary section taken in the direction of arrows 3--3 ofFIG. 1.

FIG. 4 is a fragmentary section taken in the direction of arrows 4--4 ofFIG. 4.

FIG. 5 is a fragmentary perspective view of the present improved studconstruction.

FIG. 6 is a similar view of a modification.

FIG. 7 is a fragmentary elevational view with the partitions extendinglongitudinally.

FIG. 8 is similar to FIG. 5 showing a modified stud.

DETAILED DESCRIPTION OF THE EMBODIMENTS SHOWN IN THE DRAWINGS

Referring to the drawings, an improved form of wall is shown adapted foruse between fixed structures, such as a building floor 11 and ceiling17.

A continuous channel means 13, is mounted upon said floor, using spacedfasteners 15. An opposed downwardly extending ceiling channel means 19overlies said floor channel and is similarly secured to said ceiling byfasteners 15.

While the floor and ceiling channel means have been shown as U-shaped,it is contemplated as an equivalent construction, that the respectivechannel means could be made up of opposed L-shaped members which whenassembled to the respective floor and ceiling would nevertheless provideessentially the opposed U-shaped channels shown in FIG. 3.

STEP ONE

A line or series of longitudinally spaced studs 21 is interposed betweenand projects into the respective floor and ceiling channels 13 and 19and is suitably secured with thereto with each stud, as formed andmounted, having a first more resilient side 25 and a second lessresilient side 27, and a web 23. Studs 21 are alternately arranged sothat the first and second flanges 25-27 of adjacent studs arealternately reversed.

The second less resilient flanges 27 of the studs are anchored to thechannels as by fasteners 37. The first or more resilient flanges 25 arenot anchored to the channels.

STEP TWO

Wallboard panels generally designated at 39 are applied to oppositesides of the respective studs with the wallboards on each side being inalignment and in engagement with each other at their edges throughoutthe length of the wall.

The wallboards on each side of the respective studs throughout thelength of the partition are in engagement along the registry line 43,FIG. 1 which corresponds to the central portion of the particular secondless resilient stud flange to which the wallboards at the respectiveedges are fixedly secured by fasteners 41.

Each wallboard spans at least three studs with their outer edges fixedto the second less resilient flanges 27 of the outer pair of said threestuds as by fasteners 41. In the modification shown in FIG. 7, thewallboards span more than three studs.

The central portion of each wallboard 39 is adjacent a more resilientfirst stud flange 25. In FIG. 7, central portions of the wallboardsloosely bear against adjacent resilient first flanges 25.

It is noted particularly with respect to FIGS. 1 and 2 that thewallboards 39 upon opposite sides of the partition at their respectivemeeting edges 43 are staggered or offset. Thus the meeting line 43between a pair of wallboards on one side of the wall is in registry withcorresponding central or intermediate portion of an opposed wallboard.The wallboards upon opposite sides of the wall are staggered whereby thewallboard on one side of the wall spans three adjacent studs and theopposing but staggered wallboard on the opposite side of the partitionspans two of the said three studs.

By this construction the outer upright edges of each wallboard arefixedly secured to the second flange 27 of the corresponding studwhereas the upright central portion of each wallboard yieldingly bearsagainst the corresponding resilient first flange 25 of the intermediatestud.

Thus, the individual wallboards affixed at their upright edges yieldablybear against the respective central stud and are adapted to flexinwardly and outwardly in the functioning of the present soundattenuation panel. The wallboards along their top and bottom edges arefixedly secured to the floor and ceiling channels by fasteners 41.Likewise in FIG. 7, the longitudinal edge of some wallboards bearsagainst and is affixed to channels 13 and 19.

Suitable sound absorbing pads or blankets 45, of which a pair are shown,FIGS. 1 and 2, are interposed in compression between the assembledopposed wallboards 39 and have a very definite function in the finaloperation of the present sound attenuating panel. While the presentpanel as constructed is effective as a sound attenuation panel evenwithout the sound absorbing pads interposed, an improved soundattenuation panel is provided when said pads are provided.

It has been found in operation that any inward flexing of thecorresponding wallboards due to the transmission of sound vibrationstherethrough causes a frictional rubbing action of the wallboard withrespect to the sound absorbing pad. This rubbing action transforms soundenergy to heat, thus dissipating the sound and provides an improvedsound attenuation wall partition. The compressed pad also dampenvibrations.

Glass fiber strips are shown in the illustrative embodiment, nine feetlong for example, and thus extend between the floor and ceiling and areinterposed in compression between the wallboards when assembled.

The resilent backing of each wallboard is achieved by the yieldablefirst flanges 25 providing a yielding relationship between the wallboardat its center and the supporting stud.

REPRISE

As previously indicated the broader aspect of this invention is that thestuds, when formed and mounted, have first and second flanges ofdifferent resiliency, alternately reversed. One method of accomplishingthis result is to anchor only one flange of a stud to the floor andceiling means. Thus, the stud as mounted, provides the desired result.

Alternately, the stud as formed by prior to mounting may have flanges ofdifferent resiliency, in which case mounting only one flange to thefloor and ceiling means is optional.

In stud 29, fragmentarily shown in FIG. 6, the resilient first flange 31is provided additional resiliency by a series of aligned spaced slits 33formed in the stud web.

FIG. 5 shows the resilient first flange 25 given additional flexibilityby the use of more slits. Longitudinally spaced slits 33 correspond tothose of FIG. 6. Further longitudinally spaced slits 49 are formed atthe one longitudinal edge of flange 25. Slits 49 are alternatelyarranged and staggered with respect to slits 33.

FIG. 8 is yet another modification of the stud in that the resilientfirst flange 25' is initially before assembly nonparallel to secondflange 27. Flange 25' extends outwardly at an acute angle to flange 27in the range of 5°-20° for illustration. Upon assembly of the wallboardssuch as in FIGS. 1 and 2, the resilient first flanges 25' shown in FIG.8 are then in compression and substantially parallel to plane flanges25. Resilient first flange 25' has been rendered more flexible andresilient due to the double series of staggered slots 33 and 49. .Iadd.

MY PRIOR PATENT 3,611,653

This co-pending issued patent 3,611,653, hereinafter referred to as the"tabbed stud patent" since it discloses a "tabbed stud" is referencedhere so that it may be contrasted, on the record, with the instantpatent hereinafter referred to as the "tabless stud patent" since itdiscloses a "tabless stud".

In the "tabbed stud" construction, the two flanges of a stud areanchored and of equal resilience, with one flange, however, havingintegral struck-out tabs 31. These tabs are intended to provide thebearing surface, which is thus made up of isolated, separated, smallprojections, bound to be a variety of heights, thus, providing anirregular bearing surface. Since some, at least, of the tabs 31 can andmay and probably would become twisted and deformed between the point andtime of manufacture and the point and time of use, such tabs couldpuncture and damage the formed wall surface and panels.

The tabless studs hereof will present no such problems, since they areshown in the drawings as free of tabs or protuberances. .Iaddend.

CONCLUSION

The presently preferred embodiments of the invention are shown in theappended drawings and have here been described.

The inventive concepts hereof, however are not limited to such preferredembodiments but are those defined in the claims which follow.

I claim:
 1. A method of constructing a sound attenuating wall betweenparallel fixed structures of a building comprising the steps of:a.placing a series of double-flange elongated studs in lateraldisplacement between said structures, with each stud being so mountedand formed as to have a first flange of greater resiliency and a secondflange of lesser resiliency, while arranging and mounting the studs inreversed alternation so that the more resilient flanges of spacedadjacent studs face in opposite directions and equally, the lessresilient flanges of spaced adjacent studs also face in oppositedirections; and the first flanges of one side of the wall are laterallyand alternately displaced, and equally, the second flanges of one sideof the wall are laterally and alternately displaced; b. placing wallpanels on one side of said series of studs so that the outer edges ofadjacent panels are adjacent each other and the less resilient flangesand the central portions of panels on such side are adjacent the moreresilient flanges; c. and finally, affixing the outer edges of the wallpanels on such side to the less resilient flanges on such side, with thecentral intermediate portions of the panels having resilient bearings atthe more resilient flanges of such side.[...]..Iadd., d. with each suchmore resilient flange being substantially smooth and substantially freeof external protuberances; so that substantially the entire area of eachsuch more resilient flange provides a resilient overall bearing area forthe adjacent central portion of a panel. .Iaddend.
 2. A method ofconstructing a sound attenuating wall between parallel fixed structuresof a building comprising the steps of:a. placing a series of elongateddouble flange studs in lateral displacement between said structures,with each stud having a first flange unanchored so as to be of greaterresiliency and a second flange anchored to such fixed structures to beof lesser resiliency; while anchoring and arranging the studs inreversed alternation so that the unanchored flanges of spaced adjacentstuds face in opposite directions and equally, the anchored flanges ofspaced adjacent studs also face in opposite directions; and theunanchored flanges of one side of the wall are laterally and alternatelydisplaced, and equally, the anchored flanges of one side of the wall arealso laterally and alternately displaced; b. placing wall panels on oneside of said series of studs so that the outer edges of adjacent panelsare adjacent each other and the less resilient anchored flanges;and theunanchored more resilient flanges on such one side are opposite centralportions of panels on such side; c. and finally, affixing the outeredges of the wall panels on such side, to be .[.unanchored.]..Iadd.anchored .Iaddend.flanges on such side, with the centralintermediate portions of the panels having resilient bearings at theunanchored flanges of such side.[...]..Iadd.; d. with each such moreresilient flange being substantially smooth and substantially free ofexternal protuberances; so that substantially the entire area of eachsuch more resilient flange provides a resilient overall bearing area forthe adjacent central portion of a panel. .Iaddend.
 3. A method ofconstructing a sound attenuating wall between parallel fixed structuresof a building comprising the steps of:a. placing a series of elongateddouble flanged studs in lateral displacement between said structures,with each stud as formed having a first flange of greater resiliency anda second flange of lesser resiliency; while mounting and arranging thestuds in reversed alternation so that the more resilient flanges ofspaced adjacent studs face in opposite directions and equally, lessresilient flanges of spaced adjacent studs also face in oppositedirections; and the more resilient flanges of one side of the wall arelaterally and alternately displaced, and equally, the less resilientflanges of one side of the wall are laterally and alternately displaced;b. placing walls panels on one side of said series of studs so that thecentral portions of such panels are adjacent the more resilient flangesof the studs and the outer edges of adjacent panels on such side areadjacent each other and the less resilient flanges of the studs; c. andfinally, affixing the outer edges of the wall panels on such side to theless resilient flanges on such side, with the central intermediateportions of the panels having resilient bearings at the more resilientfirst flanges of such side.[...]..Iadd.; d. with each such moreresilient flange being substantially smooth and substantially free ofexternal protuberances; so that substantially the entire area of eachsuch more resilient flange provides a resilient overall bearing area forthe adjacent central portion of a panel. .Iaddend.
 4. A method ofconstructing a sound attenuating wall between parallel fixed structuresof a building comprising the steps of:a. placing a series of elongateddouble flanged studs in lateral displacement between said structures,with each stud as formed and mounted having a first flange and a secondflange; and with the first flanges as formed and mounted having agreater resiliency than the second flanges; while mounting and arrangingthe studs in reversed alternation so that the more resilient flanges ofspaced adjacent studs face in opposite directions and equally, the lessresilient flanges of spaced adjacent studs also face in oppositedirections; and the more resilient flanges of one side of the wall arelaterally and alternately displaced, and equally, the less resilientflanges of one side of the wall are laterally and alternately displaced;b. placing wall panels on one side, offset with respect to panels on theopposite side so that the central portions of panels on one side areadjacent more resilient flanges of such side and are opposite the outeredges of the opposing panels; and the outer edges of adjacent panels oneach side are adjacent each other and are adjacent less resilientflanges of such side; and the edges of panels on one side are oppositecentral portions of panels on the other side; c. and finally, affixingthe outer edges of the wall panels on each side to the less resilientflanges on such side.[...]..Iadd.; d. with each such more resilientflange being substantially smooth and substantially free of externalprotuberances; so that substantially the entire area of each such moreresilient flange provides a resilient overall bearing area for theadjacent central portion of a panel. .Iaddend.
 5. The method ofconstructing a sound attenuation wall between parallel fixed structuresof a building which comprises the following steps:a. providing a seriesof longitudinally spaced studs between such structures and arranging andanchoring such studs to such structures, whereby, each stud has a moreresilient flange; and a less resilient flange anchored to saidstructure; while arranging the studs so that the less resilient anchored.Iadd.flanges .Iaddend.and the more resilient flanges are alternatelyand laterally displaced; b. arranging and affixing the outer side edgesof a series of wallboards to the anchored flanges of alternate studs,with the central portions of the wallboards being adjacent the moreresilient flanges of alternate intermediate studs; with the wallboardson one side being staggered with respect to the wallboards on theopposite side, so that the central portions of the wallboards are inregistry with the affixed mounted outer edges of the opposing wallboardsand, wherein, the central portions of opposing wallboards are staggeredwith respect to each other.[...]..Iadd.; c. with each such moreresilient flange being substantially smooth and substantially free ofexternal protuberances; so that substantially the entire area of eachsuch more resilient flange provides a resilient overall bearing area forthe adjacent central portion of a panel. .Iaddend.
 6. The method ofconstructing a sound attenuation wall between parallel fixed structuresof a building which comprises the following steps:a. providing,arranging and anchoring a series of longitudinally spaced double flangeand web studs between said structures whereby each stud has a moreresilient flange which is not anchored and also has a less resilientflange anchored at its ends, and wherein the more resilient unanchoredflange is thus more resilient than the anchored flange; includingarranging the studs so that adjacent unanchored and anchored flanges arealternated and laterally displaced; b. arranging and affixing the outeredges of each of a series of wallboards to the anchored flanges of theouter of three adjacent studs wherein, the central portion of eachwallboard is adjacent an unanchored resilient flange of an intermediatestud; with the wallboards on one side being staggered with respect tothe wallboards on the other side so that the central portion of onewallboard is adjacent an unanchored flange and is in registry with anaffixed mounted edge of the opposing wallboard and wherein the centralportions of opposing wallboards are staggered with respect to each otherand wherein the affixed edge portions of opposing wallboards arestaggered with respect to each other.[...]..Iadd.; c. with each suchmore resilient flange being substantially smooth and substantially freeof external protuberances; so that substantially the entire area of eachsuch more resilient flange provides a resilient overall bearing area forthe adjacent central portion of a panel. .Iaddend.
 7. A method forconstructing a sound attenuation wall between parallel fixed structuresof a building having anchor means arranged for anchoring the ends of aseries of studs longitudinally spaced along such anchor means,comprising the following steps:a. providing a series of studs, eachhaving a web and two flanges, at least one of which is normally of asubstantial degree of resilience; andanchoring the series of studs inlongitudinally spaced relation to said anchor means, with the resilientflanges alternated on opposite sides of such anchor means; by affixingthe ends of anchored flanges of alternate studs to said anchor means andleaving unaffixed the ends of the resilient flanges of the studs,whereby the anchored flanges become of even lesser resilience than whenunanchored, and whereby the unanchored flanges remain of their previouscondition of resilience; thus insuring a difference in resiliency ofanchored and unanchored flanges; b. arranging and affixing edges of eachof a series of large wallboards to the anchored flanges of the outer ofthree adjacent studs with the central portion of each wallboard beingadjacent the unanchored flanges;whereby the wallboards on one side arestaggered with respect to the wallboards of the opposite side, so thatthe central portion of one wallboard is in registry with the affixedmounted edges of the opposing wallboards, and the affixed portions ofadjacent wallboards are in registry with the central portion of anopposing wallboard.[...]..Iadd.; c. with each such more resilient flangebeing substantially smooth and substantially free of externalprotuberances; so that substantially the entire area of each such moreresilient flange provides a resilient overall bearing area for theadjacent central portion of a panel. .Iaddend.
 8. The method ofconstructing a sound attenuation wall between parallel fixed structuresof a building which comprises the following steps:a. providing,arranging and mounting a series of longitudinally spaced double flangeand web studs between such structures wherein each formed and mountedstud has its first flange more resilient than its second flange; whilearranging the studs so that adjacent more resilient and less resilientflanges are alternated and laterally displaced; b. arranging andaffixing the outer edges of each of a series of wallboards to the lessresilient flanges of the outer of three adjacent studs whereby thecentral portion of each wallboard is adjacent a more resilient flange ofan intermediate stud.[...]..Iadd.; c. with each such more resilientflange being substantially smooth and substantially free of externalprotuberances; so that substantially the entire area of each such moreresilient flange provides a resilient overall bearing area for theadjacent central portion of a panel. .Iaddend.
 9. A method forconstructing a sound attenuation wall between parallel fixed structuresof a building having means for anchoring the ends of a series of studslongitudinally spaced along such anchoring means, comprising thefollowing steps:a. arranging and providing a series of studs, eachhaving a web and two flanges, and mounting the series of studs inlongitudinally spaced relation to said anchoring means, with the studsbeing so formed and mounted that one flange of each stud is considerablymore resilient than a second flange of each stud, with the moreresilient flanges alternated on opposite sides of such anchoring means;b. providing, arranging and affixing the outer edges of each of a seriesof large wallboards to the less resilient flanges of the outer pair ofthree adjacent studs with the inner intermediate portion of eachwallboard being against the more resilient flanges of an intermediatestud.[...]..Iadd.; c. with each such more resilient flange beingsubstantially smooth and substantially free of external protuberances;so that substantially the entire area of each such more resilient flangeprovides a resilient overall bearing area for the adjacent centralportion of a panel. .Iaddend.
 10. A method for constructing a soundattenuation wall between parallel fixed structures of a building havingmeans for anchoring the ends of a series of studs longitudinally spacedalong such anchoring means, comprising the following steps:a. providingand arranging a series of studs, each having a web and two flanges; andmounting the series of studs in longitudinally spaced relation to saidanchoring means and anchoring the studs to said anchoring means; withthe more resilient flanges alternated on opposite sides of suchanchoring means; b. arranging and affixing the outer edges of each of aseries of large wallboards to the less resilient flanges of the outerpair of three adjacent studs with the central portion of each wallboardbeing against a more resilient flange of an intermediate stud;wherebythe wallboards on one side of the wall are staggered with respect to thewallboards of the opposite side, so that the central portion of onewallboard, adjacent a more resilient flange, is in registry with theaffixed mounted edges of the opposing wallboards, bearing against a lessresilient flange, and the affixed portions of adjacent wallboards,bearing against a less resilient flange, are in registry with thecentral portion of an opposing wallboard, adjacent a more resilientflange; thereby providing a staggered resilient mounting of wallboardsupon and alongside opposite sides of said studs.[...]..Iadd.; c. witheach such more resilient flange being substantially smooth andsubstantially free of external protuberances; so that substantially theentire area of each such more resilient flange provides a resilientoverall bearing area for the adjacent central portion of a panel..Iaddend.